SOLAR POWERED BIO-DIESEL PRODUCTION UNIT

P R E S E N T E D B Y :

A D E L M O H A M M A D A H M A D H I B A L A

H U S S I E N E L - B A S S I O U N Y M O H A M M E D A L I

W A S E E M W A F E E K

S U P E R V I S O R S :

P R O F . D R . H A M D Y A S H O U R

D R . E S S A M A B D E L - M O U L A

Solar Powered Automated Biodiesel Processor Unit

1

ACKNOWLEDGEMENT

2

ACKNOWLEDGEMENT

We are most grateful to our supervisors Prof.Hamdy Ahsour and Dr.Essam Abd EL-Mola

We thank The Academy of Scientific Research and Technology for thier financial support.

And we also thank Eng. Mohammed El-Saharty for his help.

Special thanks for staff of electrical and control department for co-operating and facilitating our mission for work in this project.

Objective 3

The purpose of this project is to develop a Fully Automated Bio-diesel Production Unit, in order to fulfill the rising demand on fossil fuels and energy and the declination of the world production of traditional sources of energy but the main target is to achieve this by a sustainable technique. By "Reusing" the wasted oils we treat it chemically and have two products out of it the main product is the "Biodiesel" the secondary product is the "Glysrol".

This project can be made either on small scale to serve small needs or on larger scale for major industries. The control method will depend on the type of industry this unit will serve in.

Time schedule for first term

30-12-2012

4

Project Outline

Introduction to Biodiesel

MIMIC Diagram

Automation System

SCADA System

Mechanical Design

Practical Implementation

5

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

6

Introduction

• Wind Energy

• Hydro Energy

• Geothermal

• Solar energy

• Biodiesel

• Experiments

7

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

8

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

In our case it is impossible to use it because it needs a lot of area and permanent source of water and we want our unit is portable

9

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

10

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

11

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

12

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

What is Biodiesel

13

Biodiesel is a fuel for diesel trucks, cars, buses and tractors. It is usually made from soybeans, a crop grown by farmers.

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

14

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

Why Biodiesel ? 15

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

Emissions of Biodiesel 16

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

Biodiesel on environment 17

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

Algae

Palm oil

Jetropha

Used cooking oil

18

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

Steps of Biodiesel Production

19

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

ASTM Standards

Completion reaction

Specific gravity

Clarity

Ph

Cloud point

Soap content

Water content

20

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

The By-Product “Glycerol” Heating glycerol to 59 c to vaporize

the methanol

Glycerin is used in animal feeds, hand creams, toothpaste, soaps, and lubricants.

21

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

There is four experiment done we can divide it into two sections

The first section at small quantities

The second section on patch 10 liter

22

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

First one on 200 ml used oil and 50 ml methanol and 2 gm Na-Oh

23

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

The Second one we use 500 ml of used oil with 125 ml of methanol and 3 or 4 gm of Na-Oh

24

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

25

Introduction

•Wind Energy

•Hydro Energy

•Geothermal

•Solar energy

•Biodiesel

•Experiments

First one done but there is some fault in step of washing the motor mixer speed was over and make the biodiesel soap.

26


W A S E E M W A F E E K

27

MIMIC Diagram

Mimic work

•I/O of the system

•AVR pins layout

•Code

•Simulation

•Hardware

Outline

Flow chart of the system

Inputs and outputs of the system

AVR pins layout

Code

Simulation

Making the hardware:

1. Drawing the system

2. PCB boards

3. Wiring

4. the mimic body design

28


•AVR pins layout

•Code

•Simulation

•Hardware

What is Mimic ? Mimic is graphical representation on HMI or

SCADA or even on a panel with the help of LED,S and flow diagram.

MiMiC is used to test automation system application software

Train operators before startup, capital project costs and schedules are decreased.

For testing automation system enhancements and re-training or qualifying operators

Operational Excellence goals are met, business results are increased and cost decreased.

29

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Mimic Design

30

Mimic work 40 * 50 * 45 cm


•AVR pins layout

•Code

•Simulation

•Hardware

Inputs :

Digital inputs:

1. Start button

2. Stop button

3. Man/auto switch

4. Bottle detection sensor

Analog inputs :

1. Level sensor

2. Density sensor

3. Oil temperature sensor

4. Water temperature sensor

31

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Outputs: 1. Water pump led 2. Water heater led 3. Water valve led 4. Sprinkler led 5. Oil heater led 6. Oil valve led 7. Chemical valve led 8. Mixer led 9. Air pump led 10. Out valve 11. Conveyor led 12. Start led 13. Stop led

32

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Atmega32 Pin layout

33

LCD

Outputs

Analog inputs

DO & DI

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

PORTA(ADC):

PINA.0= Level sensor

PINA.1=water temp sensor

PINA.2=density sensor

PINA.3= oil temp sensor

PINA.4= Req. oil

PORTB:

ALL PINS TO LCD

PINB.3= Start button

34

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

PORTC: PORTD:

PORTC.0= water valve PORTD.0= mix motor

PORTC.1= sprinkler PORTD.1= conv motor

PORTC.2= out valve PIND.2 = stop button

PORTC.3= water pump PIND.3= man/auto

PORTC.4= heater oil PIND.4= bottle detection

PORTC.5= start led PORTD.5= oil valve

PORTC.6=air bubble PORTD.6= chemical valve

PORTC.7=stop led PORTD.7=water heater

35

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Simulation

36

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

1- System Diagram

37

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

2-PCB works :

Main board

Manual board

Power supply board

Distributer board

38

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Main board

39

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Manual board

40

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

41

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

42

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Power supply

43

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

distributer

44

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

45

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

46

Part 1

Part2

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Part2

47

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Part2

48

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Number Switches

1 Air pump

2 Water pump

3 Out valve

4 Chemical valve

5 Oil valve

6 Water valve

7 Conveyor motor

8 Bottle detection

9 Water sprinkler

10 Mixer

11 Oil heater

12 Water heater

49

Wiring trace table Manual switches

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Numbers Output and inputs

13 +5v

14 GND

15 Density pot

16 Oil temp pot

17 Level pot

18 Water temp pot

19 Start button

20 GND

21 GND

22 +5v

23 Start led

24 Man / auto led

25 Man/auto switch

26 Stop led

27 Req. diesel

28 Stop button

50

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Number Outputs and inputs

40 Water pump led

41 Water heater led

42 Water valve led

43 Sprinkler led

44 Oil heater led

45 Oil valve led

46 Chemical valve led

47 Mixer led

48 Air pump led

49 Out valve

50 Conveyor led

51

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

52

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

53

Mimic work


•AVR pins layout

•Code

•Simulation

•Hardware

Programming language used

We make the code of the process in two programming languages :

1- C programming language for AVR

2- LADDER programming language for Zelio PLC

54

Mimic work

Liquid Discrimination 55

Liquid Discrimination

According to the operation we need to make two separations one between the Glycerol and Bio-diesel and the other with water and Bio-diesel

Density

pH

Viscosity

Ultrasonic

Color detection

Camera

Capacitance

56


•Density

•pH

•Viscosity

•Ultrasonic

•Color detection

•Camera

•Capacitance

Density of Bio-diesel is in range of 850 kg/m^3

Density of water is 1000 kg/m^3

Density of glycerol is 1200 kg/m^3

57


Density

pH

Ultrasonic

Color detection

Camera

Capacitance

Unwashed biodiesel will have a pH around 9 and washed biodiesel will be closer to 7

pH of Water is 7

pH range of 100% Glycerol: 6.9 - 7.6

The pH are so close in addition we didn’t find it easily

58


Density

pH

Ultrasonic

Color detection

Camera

Capacitance

59

Liquid discrimination

Density

pH

Viscosity

Ultrasonic

Color detection

Camera

Capacitance

There’s a lot of ideas

Camera and image processing

Color detector

60


According to the operation we need to make two separations one between the Glycerol and Bio-diesel and the other with water and Bio-diesel

Density

pH

Viscosity

Ultrasonic

Color detection

Camera

Capacitance

61

Micro based Capacitance sensor

62

Micro-based Capacitance sensor

The capacitive Sensor method toggles a microcontroller send pin to a new state and then waits for the receive pin to change to the same state as the send pin. A variable is incremented inside a while loop to time the receive pin's state change.

63

Micro-based Capacitance sensor

64


A D E L M O H A M M A D

Automation System 65

Automated system

Automated System.

Programmable Controller (PLC) .

Hardware Configuration.

Sensor.

Software Configuration.

66

AUTOMATION SYSTEM

Automated System.



PLC Component .

I/0 Interface .

Sensor.


Operational Programming,

Controller ( PLC).

Command Signal.

Machine ( Heater – Motor Mixing – Air Bubbler….) .

Measuring Signal (Level Sensor – Temperature Sensor ….)

Material (Oil – Methanol – Water ). Product ( Biodiesel )

67

Automation System

Automated System.



Sensor.


Programmable controller :

Hard ware Configuration.

PLC Component :

Central Processing Unit ( Processer - Power Supply - Memory ) .

68

Digital I/0

Analog i/0

CPU

PS

Automated System

Automated System.



Sensor.


The I/O interfaces :

provide the connection between the CPU and the information providers (inputs) and controllable devices(outputs).

69

Automated System

Automated System.



Sensor.


Input Interface :

70

Level Sensor

Temperature Sensor

Rectifier Circuit

Digital Circuit

Automated Circuit

Automated System.



Sensor.


71

Digital circuit

Automated system

Automated System.



Sensor.


72

Analogue input conditioning Circuit

Automated System

Automated System.



Sensor.


Output Interface :

73

Automated System

Automated System.



Sensor.


The Digital Input/output System

Digital Input : ( Level Sensor – Push Button )

Digital output : (Valve – Motor –Heater –Air Bubbler )

The Analog Input / Output System

:Analog Input :

(Temperature Sensor –Level Sensor – Density Sensor)

74

Automated System

Automated System.



PLC Component .

I/0 Interface .

Sensor.


75

Ultrasonic Sensor

Automated System

Automated System.



Sensor.


Ultrasonic Sensor: Transmitters, receiver and control circuit.

Wire connecting .

Provide 2cm - 400cm.

Test distance = (high level time × velocity of sound (340M/S) / 2.

Min rang 2cm ,Max Range 4m , Measuring Angle 15 degree.

Analog & Digital Sensor .

76

Automated System

Automated System.



Sensor.


77

RTD Temperature sensor:

Automated System

Automated System.



Sensor.


This temperature sensor is based on a thermostat.

not used for high temperatures

2 line output: length 30cm.

Temperature Range: −40 °C to. +150 °C.

78

Automated System

Automated System.



Sensor.

Software Configuration

Software Configuration:

Code of Ultrasonic .

Code Of Temperature Sensor

Flow chart

79

Automated System

Automated System.



Sensor.


Code of Ultrasonic in PLC :

80

Automated System

Automated System.



Sensor.


Code Temperature Sensor in plc :

81

Automated System

Automated System.



Sensor.


82

Automated System

•Automated System.

• Programmable Controller (PLC) .

•Hardware Configuration.

•Sensor


83


MOHMMAD ALI

SCADA system 84

•Introduction

•SCADA Components

•Advantages Of SCADA systems

•SCADA Architecture

•Screens

•Trends

•Alarms

•Guide

85

SCADA SYSTEM

SCADA SYSTEM

Introduction

SCADA Components

Advantages Of SCADA systems

SCADA Architecture

Screens

Trends

Alarms

Guide

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

86

SCADA SYSTEM

Stands for supervisory control

And data acquisition.

SCADA systems are used in

industrial processes: steel

making, power generation

(conventional and nuclear) and

distribution.

87

SCADA SYSTEM

Components of SCADA System.

Field Instrumentation.

Sensors, devices to control.

Remote Terminal Units. RTU Vs. PLC

Communications Network. Equipment needed to transfer data to and

from different sites

Central Monitoring Station Collecting information gathered by the

remote stations to generate the necessary action

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

88

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

89

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

90

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

91

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

92

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

93

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

94

SCADA SYSTEM •Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

95

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

96

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

97

98

SCADA SYSTEM

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

99

Text help •Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

100

Symbol help

•Introduction

•SCADA Components



•Screens

•Trends

•Alarms

•Guide

Mechanical Construction 101

Mechanical Constriction

102

Water tank

Oil tank

Chemtank

Mix tank

103

Galvanic steel sheet 2.5 * 1.2 meter and 3 mm thickness

All the wilding work was made using argon wilding.


104

25 L 30 cm 20 L 25 cm

52.8 L 40 cm 46 L

35 cm



A H M A D H I B A L A

Practical Implementation 105


System Block Diagram

Electrical components

Power Calculation

PV system Rating

Comparison

Conclusion and Future Work

106


•System Block Diagram

•Electrical components

• Power Calculation

• PV system Rating

• Comparison

• Conclusion and Future Work

107





• Comparison


108

The Three tanks Control Panel

Mixing tank MIMIC Relay and isolation Panel

1500 W inverter Power supply panel 2*74 Ah Battery

What is missing ?!!







• Comparison


109

Ultrasonic Level Sensor in all tanks. Range: 2 cm to 4 m.

RTD Temperature sensor Range -84 C to 324 C Disadvantage : nonlinear

Start\Stop PB Start\Stop indicator






• Comparison


110

Two Heaters 220V, 33 ohm 6.5 A, 1500 W

Air bubbler 220V

Three Valves for water, oil and chemical tank






• Comparison


111

Two Valves. For Water and glycrol And Biodiesel Motor mixer

Two Valves. For Water + Shower Oil






• Comparison


112






• Comparison


113

Wiring Diagram and tables in book page 132 to 134






• Comparison


Sizing of PV system

Major system components

• PV module • Solar charge controller • Inverter • Battery • Load

114






• Comparison


115

Calculate power

Calculate energy

Sun time hours

PV rating =Energy/ factors

Decide PV module rating from market

#of PVs = total rating/module rating

Inverter = power * 1.25 (static loads) Inverter = power * 3 (dynamic loads)

Fators: Sun hours Maintan and eff = 0.75

charge controller = SC current of PV array x 1.3

Battery Capacity (Ah) = Wh /(0.85x 0.5 x battery voltage)






• Comparison


116

We need max of 750 Wh to supply the main loads

We need max of 170 Wh to supply the control circuits






• Comparison


The two batteries 74 Ah 12 V DC

Total capacity = 2*74Ah*12V= 1776 Wh.

So 50% of the capacity = 888 Wh.

117

One battery 38 Ah 12 V Dc Capacity = 12*38 =456 Wh. So 50% of the capacity = 228 Wh.






• Comparison


118

100 W 18 V 5.5 A






• Comparison


119

75W 18 V 4.2 A






• Comparison


120

Modified Sine wave inverter 1500 W

True Sine wave inverter 400 W






• Comparison


121

Max from the two panels = 9.5 A Max from 75 W panel = 4 A When all in parallel = 13 A Charging from 55% of the two 74 Ah To 95 % in 1 h and 45 minute






• Comparison


122

Discharging

123

25.7 V

24.0 V

23.9 V

23.7 V

23.6 V

23.5 V

23.4 V

23.3 V

24.9 V

24.8 V

24.7 V

24.7 V

24.9 V

23.0 V

22.9 V

22.8 V

22.7 V

22.6 V

22.5 V

22.4 V

22.3 V

24.4 V

Duration 0 20 120 75 42 30 30 24 0 60 150 90 0 0 45 60 50 50 19 30 10 0

0

20

40

60

80

100

120

140

160

Ax

is T

itle

Duration

W.H

O.H

25.7 No load 24.0 to 23.3 Heating in 5 m 30 s

MX

24.9 no load 24.8 to 24.7 mixing in 5 m

24.9 no load (separation)

N.L

24.9 no load 23.0 to 22.3 heating in 4 m 30 s 24.4 no load (separation)






• Comparison


124

Cont. Discharging

Enough energy to heat oil to 50 C only






• Comparison


125

Calculate power = 1700 w

Calculate energy = 1200wh

Sun time hours =10 h

PV rating =1200/ (10*0.75) = 160W

PV module rating = 100 W

#of PVs = 160/100 =1.6 =2

Inverter = 1500* 1.25= 1900 Inverter = 200* 3 =600

Fators: Sun hours Maintan and eff = 0.75

charge controller = 10 x 1.3 =13

Battery Capacity (Ah) = 1200/(0.85x 0.5 x 12) = 210 ah






• Comparison


Comparision

126






• Comparison


Comparision

127

Our system is considered as prototype still, but it can produce 20 litters in less than 18 hours. Cost with PV system and SCADA = 5200 $ Cost with PV system and no SCADA =4500$ Cost without PV and without SCADA = 1500 $






• Comparison


128

Heating Value of Biodiesel and Diesel

British thermal unit (Btu) is defined as the amount of heat required to raise the temperature of one pound of water by one degree Fahrenheit.






• Comparison


With 20 litters per time processes

1 litter = 0.264172 gallon.

20 litters = 5.28344 gallon

Heat content = 5.28344 *118269 Btu/gal = 624867.16536 BTU

To convert BTU to kWh

kWh= 0.00029307107017 × BTU

E(kWh) = 0.00029307107017 × 624867.16536

= 183.13 kWh

Efficiency = (183 – 1.5)/183 = 99%

129

―2004 Biodiesel Handling and Use Guidelines‖, US Department of Energy, US Department of Energy, ―A Comprehensive Analysis of Biodiesel Impacts on Exhaust Emissions‖, US Environmental Protection






• Comparison


Conclusion The MIMIC diagram was essential to understand

the process and get used to the automation idea,

The difficulty of circuits and the relative complexity of the code lead to the use of another and higher automation level.

The PLC was used because it is fast and reliable and very compatible to such application, the

program was made very elaborative.

The SCADA with both the HMI and the PC station helps to monitor and control and ensure a full access and good insight and useful to help improve the system.

With sunny weather and long sun time during the year in Egypt,

the PV cells charge the batteries during day light through the MPPT and the battery charge, the PV cells could supply a current of 13 A in a sunny mid temperature day.

130






• Comparison


Ultrasonic sensor

Temperature sensor

High Voltage Separation

Relay Panel wiring

PV system

Capacitance sensor

More Experiments

131

Engineering

SOLAR POWERED BIO-DIESEL PRODUCTION UNIT